Installation
CONTINUOUSLY VARIABLE TRANSMISSIONINSTALLATION
1) Attach the ST to converter case.
ST 498277200 STOPPER SET
2) When completely overhauling the transmission, refill approx. 10 l (2.6 US qt, 8.8 Imp qt) of CVTF through the transmission right side plug, and install the plug.
CAUTION:
Always use specified CVTF or equivalent. Using other fluid than specified or equivalent will cause malfunction.
NOTE:
Use a new gasket.
Tightening torque:
35 Nm (3.6 kgf-m, 25.8 ft-lb)
3) Replace the front differential side retainer oil seal.
NOTE:
^ Be sure to replace the differential side retainer oil seal with a new part whenever the front drive shaft is removed from the transmission.
^ When a new differential side retainer oil seal has been installed, replacement is not required.
4) Install the cushion rubber on the transmission.
Tightening torque:
40 Nm (4.1 kgf-m, 29.5 ft-lb)
5) Mount the transmission onto the transmission jack.
6) Strike and bend the transmission hanger of transmission rear with a soft rubber hammer etc. so that it gets in contact with the transmission case.
CAUTION:
Do not apply extra overload or impact to the transmission case.
7) While lifting up the transmission gradually, install the transmission to the engine.
CAUTION:
This operation requires at least two persons.
NOTE:
Keep the engine level.
8) Install the two engine connecting bolts and two nuts (lower side).
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
9) Secure the transmission rear crossmember to the vehicle body.
Tightening torque:
T1: 35 Nm (3.6 kgf-m, 25.8 ft-lb)
T2: 75 Nm (7.6 kgf-m, 55.3 ft-lb)
10) Remove the transmission jack.
11) Lower the vehicle.
12) Remove the ST (ENGINE HANGER).
13) Install the four engine mounting bolts (upper side).
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
14) Install the left and right transmission mounting brackets.
NOTE:
^ Install to the left side of vehicle first because the engine inclines to the left.
^ Temporarily tighten the bolt arrowed in the figure.
Tightening torque:
75 Nm (7.6 kgf-m, 55.3 ft-lb)
15) Set the ST1 to vehicle body and lift up the engine unit slightly.
ST1 99099AJ000 ENGINE HANGER
ST2 99099AJ010 CHAIN BALANCER
CAUTION:
^ Set so that the chain sling does not contact the engine parts.
^ Set the arms of ST (ENGINE HANGER) at the locations shown in the figure.
16) Remove the bolts from ST (SPECIAL TOOL H4).
17) Remove the bolt and nut to remove ST (SPECIAL TOOL H4).
18) Temporarily attach the front cushion rubber with bolts.
19) Install the bolt and nut to the front cushion rubber.
20) Tighten the bolts and nuts of front cushion rubber.
NOTE:
Always start tightening from the bolts on the engine side.
Tightening torque:
T1: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
T2: 45 Nm (4.6 kgf-m, 33.2 ft-lb)
21) Remove the ST (ENGINE HANGER and CHAIN SLING).
22) Install the stopper rod.
Tightening torque:
36 Nm (3.7 kgf-m, 26.6 ft-lb)
23) Install the nut to the transmission mounting bracket.
Tightening torque:
45 Nm (4.6 kgf-m, 33.2 ft-lb)
24) Remove the ST (STOPPER SET) from converter case.
25) Match the torque converter screw hole with drive plate hole to install the bolt.
CAUTION:
^ Do not drop the mounting bolt in the converter housing.
^ Do not damage the mounting bolt.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
26) Install the remaining three bolts by rotating the crank pulley a little at a time in the same direction as engine revolution.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
27) Install the service hole plug.
28) Install the starter.
29) Lift up the vehicle.
30) Tighten the single mounting bolt of transmission mounting bracket.
Tightening torque:
75 Nm (7.6 kgf-m, 55.3 ft-lb)
31) Set the ST to side retainer.
ST 28399SA010 OIL SEAL PROTECTOR
32) Replace the circlip of the drive shaft with a new part.
33) Insert the front drive shaft spline section into transmission and remove the ST (OIL SEAL PROTECTOR).
34) Insert the drive shaft into the transmission securely by pressing the housing from outside of the vehicle.
35) Install the CVTF CVT inlet hose and CVTF CVT outlet hose.
NOTE:
Use new CVTF CVT inlet hose and CVTF CVT outlet hose.
36) Insert the ball joint into housing and secure with bolt.
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
CAUTION:
^ Do not apply grease to the tapered portion of ball stud.
^ Before tightening, make sure the lower side of housing and stepped section of ball joint are in contact.
37) Install the stabilizer link.
Tightening torque:
60 Nm (6.1 kgf-m, 44.3 ft-lb)
38) Connect the tie-rod end and knuckle arm, and attach the castle nut.
Tightening torque:
27 Nm (2.75 kgf-m, 19.9 ft-lb)
CAUTION:
When connecting, do not hit the cap at the bottom of tie-rod end with hammer.
39) After tightening the castle nut to the specified tightening torque, tighten it further within 60° until the cotter pin hole is aligned with slot in the nut. Fit the cotter pin into the nut, and then bend the pin to lock.
40) Install the propeller shaft.
41) Install the universal joint.
42) Install the plate assembly to transmission.
Tightening torque:
T: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
43) Install the washer and snap pin to the shifter arm.
44) Install the heat shield cover.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
45) Install the center exhaust pipe.
46) Install the under cover.
47) Lower the vehicle.
48) Remove the engine hanger rear for turbo model and install the engine hanger rear for non-turbo model.
Tightening torque:
16 Nm (1.6 kgf-m, 11.8 ft-lb)
49) Install the engine harness connector to the engine hanger rear, connect the harness connector, and install the harness connector bracket.
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
50) Install the throttle body.
51) Install the manifold absolute pressure sensor.
52) Connect the following harness connectors.
^ Transmission harness connectors
^ Transmission radio ground terminal
^ Inhibitor harness connector
Tightening torque:
13 Nm (1.3 kgf-m, 9.6 ft-lb)
53) Install the battery cable bracket, and install the battery cable clip to the bracket.
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
54) Attach the grille bracket.
55) Install the air intake boot assembly.
56) Install the air intake duct.
57) Install the front wheels.
58) Connect the battery ground terminal.
59) Refill differential gear oil to adjust the differential gear oil amount. Differential Gear Oil Adjustment
60) Refill CVTF to adjust the CVTF amount. CVT Fluid Level Adjustment
61) Perform the variator chain break-in.
CAUTION:
Always execute the variator chain break-in after the replacement of the following.
^ Variator chain replacement
^ Primary pulley and secondary pulley replacement
62) Perform Clear Memory 2 operation. Clear Memory Mode
63) Perform learning control promotion. Programming and Relearning
64) Execute the rear differential inspection mode. Initial Inspection and Diagnostic Overview
CAUTION:
Always execute the rear differential inspection mode at the replacement of the following.
^ Replacement of transmission assembly
^ Replacement of front differential hypoid gear set
65) Perform the road test to make sure there is no fault. Road Test